«EN 1563 Yeni Nesil Dökme Demirler»

«EN1563 - New Generation Ductile Iron»Seyfi Değirmenci

Bülent ŞirinBert Duit

(Componenta)

7.Oturum: Süreçler ve Kontrol7th Session: Process and Control

Oturum Başkanı/Session Chairman: Mustafa Akyürek (Anadolu Döküm San. Tic. A.Ş.)

Oturumlarda yer alan sunumlar 15 Eylül 2014 Pazartesi tarihinde kongre web sayfasına (kongre.tudoksad.org.tr) yüklenecektir.

22.10.20152

EN 1563 YENİ NESİL DÖKME DEMİRLER

TURKİSH FOUNDRYMENSOCİETYSEPTEMBER11-13.2014 İSTANBUL

Seyfi Değirmenci, Bülent Şirin, Bert Duit

AGENDA

• Componenta Company overview

• SSF, Solution Strengthened Ferrite

• Mechanical properties

• Machinability

• Some examples of SSF designs

• Experiences

• Cost impact, how to act

• Summary

3

22.10.20154

COMPANY OVERVİEW

4

COMPONENTA: The second largest independent cast component supplier in Europe

5

• Componenta serves its customers by offering

them casting solutions covering the whole value

chain from engineering to finished components.

• The Group’s foundries and machine shops are

located in Turkey, Finland, the Netherlands and

Sweden. In addition, the Group has three forges

in Sweden.

• Componenta’s customers are manufacturers of

vehicles, machines and equipment in various

industries: Global players such as Volvo,

Caterpillar and Wärtsilä. Long-term customer

relationships and strong credit ratings.

• Componenta’s shares are listed on the NASDAQ

OMX Helsinki.

Ready to serve - strong local presence

in key markets

6

Strong market positioning in selected

customer industries

7

• Produces to leading OEM’s and has two own

trademarks: DJ and MAXX

• Fine-tuned component features by advanced

engineers: reduced weight, lower CO2 emissions,

improved strength and fuel economy.

Construction and mining(19% of sales)

Heavy trucks(31% of sales)

Automotive

(15% of sales)

Agricultural machinery(17% of sales)

Machine building

(18% of sales)

Chassis parts

Engine parts

Gearbox

and

transmission

partsAxle parts

Hydraulic parts

Axle housing

Chassis & structure

Engine

blocks

&

cylinder

heads

Transmission

& gearbox housing

• Solutions for all major players using 3D CAD data

and finite element analysis

• Components supplied to loaders, haulers,

excavators and graders.

• Volvo Trucks a customer since 1960’s

• Customized solutions through optimized

component design and use of alternative materials

to achieve vehicle weight goals

• Large segment with diverse sub-segments including:

holding blades for windmills, railway equipment,

compressor equipment industrial gears etc.

• Complex advanced engineering and co-design

activities to meet technical challenges

• Cast components from iron to aluminium, rough or

machines, possible surface treatment.

Light alloy

wheels

Rear

travers

Cylinde

r heads

Air

intake

system

Holding

bladesAtlas Copco

compressor

Wärtsilä

diesel

engine

OUR BROAD CUSTOMER BASE

supports stability and innovation

15%

Automotive

17%

Agricultural Machinery

18%

Machine Building

19%

Construction and Mining

31%

Heavy Trucks

22.10.20158

Heavy Trucks Construction and Mining

Machine Building

Agricultural

Machinery Automotive

31% 19% 18% 17% 15%

WE WANT TO CONTINUE TO SERVE

OUR CUSTOMERS for the next 100 years

22.10.20159

OUR CAPABILITIES BY FOUNDRY

TYPE OF THE LINE BOX SIZE

TYPICAL

MAXIMUM

PRODUCT

WEIGHT

CAPACITYMINIMUM SERIAL/

YEARLY VOLUMEMATERIALS

BOX SIZE (mm) HEIGHT (mm) (kg)LINE

(tons/year)

FOUNDRY

(tons/year)

Moulds/serie or

tons/year

Iron foundries 320,000

Finland 68,000

PoriDisa 2013 480 x 600 150 / 245 20 9000

18,00050 moulds

GJL, GJS, SSFHWS 750 x 650 250 / 250 100 18,000 10 moulds

Högfors HWS 1,160 x 960 350 / 350 350 34,000 20 moulds GJL, GJS, SSF, ADI

Suomivalimo Furan handmouldingMAX

2,600 x 3,600MAX. 2,500 5,000 16,000 - GJL, GJS, SSF, ADI

Netherlands 92,000

Weert HWS 1,250 x 850 400/400 350 36,000 15 moulds GJL, GJS, SSF, ADI

Heerlen HWS HWS 850 x 630 330/330 150 36,000 30 moulds GJL, GJS, SSF, ADI

Heerlen FuranFuran semi-

automatic moulding

2,200 x 1,250 MAX. 1,600

3,500 20,000 20 tons GJL, GJS, SSF, ADI2,500 x 1,750 MAX. 2,000

3,000 x 1,750 MAX. 1,600

3,300 x 2,000 MAX. 1,600

Turkey 160,000

Orhangazi

L1 +GF+ 700 x 900 360/360 100 27.000

160,000 100 tons GJL, GJS, GJV, SSF

L2 HWS 1,250 x 900 400/400 300 32.000

L3 +GF+ 700 x 900 360/360 100 32.000

L4 Disa 2013 650 x 535 200/370 20 9.000

L5 Disa 2120 850 x 650 260/400 55 16.000

L6 HWS 1,100 x 900 350/350 250 34.000

L7 HWS 1,960 x 1,260 400/400 500 36.000 22.10.2015

Advanced properties of

CERTIFIED SSF MATERIAL

• Superior yield strength – 13 to 27% improvement

• Even 3.3 times better elongation and improved fatigue properties

• Lighter structures of component enables higher loads with same

wall thickness or thinner sections

• Excellent machinability in certain cases

• Less variation in mechanical properties

• Enhanced performance in elevated temperatures

• Possible to replace Steel fabricated parts, like forgings or welded

constructions

22.10.201511

35 % WEIGHT REDUCTION

- from welded steel construction to SSF casting

•

22.10.201512

STARTING POINT• Welded construction to be developed

into a cast component

• Modular products for two Harvester

Designs (Machine Building)

APPLIED

SOLUTION• Design release;

made by customer in

close cooperation

with Componenta

• Desired material: 2nd

generation SSF and

one ADI partEND RESULT

• 4 functions in one product compared to

welded construction

• 35% weight savings

• Machining savings

• Remarkable process phase savings

• Improved and even material properties

• Excellent end product for the customer

22.10.201513

SSF

Solution Strengthened

Ferrite

1

3

What is HiSi / SSF ?

• HiSi / SSF : High Silicon / Solution Strengthened Ferritic spheroidal graphite

cast iron.

• A high strength ductile cast iron quality alloyed with

silicon (3.2 – 4.3 %, depending upon quality) instead of

manganese and copper or tin.

• Alloying level of silicon is constant per SSF-grade, unlike

normal ferritic-pearlitic grades, where alloying level of

manganese and copper depends on casting size and

geometry.

• Constant Si-level, independent of casting size and

geometry, resulting in a fully ferritic matrix ( max 5%

pearlite) and homogeneous properties in all sections of

the casting

• Improved properties are caused by solid solution

strengthening of the ferrite matrix by silicon.

14

History

1998 -

2004 -

2012 -

Developed in the early 90’s by Volvo, Scania and Swedish Foundry institute

Swedish Standard, SS 140725 for grades 450-15 and 500-10

– Lower values for elongation proposed to make it more acceptable for

(German) Foundries

ISO 1083:2004, only grade 500-10 described

– In Normative Annex A

EN 1563:2012, 3 normative grades mentioned:

– GJS-450-18

– GJS-500-14

– GJS-600-10 : New grade introduced, mainly developed by

Componenta (Joop Kikkert) as an alternative for forged

steel or +GF+ Sibodur

15

22.10.201516

MECHANICAL PROPERTIES

Influence of Silicon on Mechanical properties

17

Comparison of Mechanical Properties(blue row values for SSF, white normal ferritic-pearlitic grades, light pink ausferritic (ADI))

Material Designation 0.2% proof

strength

Tensile

Strength

Elongation Brinell

hardness

range

Modulus of

Elasticity

Un-notched

Impact

Energy

Rp0.2 Rm A HBW E (at RT) unnotched notched

Mpa Mpa % kN/mm2 J Mpa Mpa

min. min. min. min. typical typical

1E1477 EN-GJS-400-18-LT 240 400 18 130-175 169 120 195 122

1E0356 EN-GJS-450-10 310 450 10 160-210 169 80 210 128

1E4677A EN-GJS-450-18 350 450 18 170-200 170 100 210 130

1E0596B EN-GJS-500-7 320 500 7 170-230 169 70 224 134

1E4677B EN-GJS-500-14 400 500 14 185-215 170 80 225 140

1E0596A EN-GJS-600-3 370 600 3 190-270 174 40 248 149

1E4677C EN-GJS-600-10 470 600 10 200-230 170 70 275 165

1E1122 EN-GJS-700-2 420 700 2 225-305 176 20 280 168

EN-GJS-800-2 480 800 2 245-335 176 15 304 182

EN-GJS-900-2 600 900 2 270-360 176 - 304 182

EN-GJS-800-8 500 800 8 260-320 163…170 110 375 225

1E1495 EN-GJS-900-6 600 900 6 280-340 100 400 240

Fatigue limit

(rotating bending)

(dia. 10.6 mm)

EN 1563:2012 and EN 1564:2012 - Mechanical properties measured on test pieces from cast samples

(for relevant wall thickness t ≤ 30 mm)

Similar

CAT Spec

18

RmRm

Rm

Rm

Rm

0,2% Proof Strength vs Tensile StrengthFor equal tensile strength higher yield strength for SSF

19

Ratio Rp0,2 / Rm for pearlitic and SSF cast iron

Suomivalimo, GJS 500, Ratio Rp0,2/Rm

0,4

0,5

0,6

0,7

0,8

0,9

300 320 340 360 380 400 420 440 460 480 500 520

0,2 % Proof strength (MPa)

Ra

tio

Rp

0,2

/Rm GJS-500-7 (n = 828)

GJS 500-14 (n=293)

Ratio Rp0,2/Rm

increases with

increasing Rp0,2 for

SSF

Design are based

upon Rp0,2 instead of

Rm, weight savings

possible

20

Elongation vs. Yield StrengthSFF Combination of high yield with high elongation

0

3

6

9

12

15

18

240 260 280 300 320 340 360 380 400 420 440 460 480

Yield Strength (MPa)

Elo

ng

ati

on

(%

)

GJS – 700 - 2

GJS – 500 - 7

GJS - 600- 3

GJS -600 - 10

GJS – 500- 14

GJS – 450 -10

GJS – 450 - 18

SSF ductile cast irons

500

ADI 800 - 8

21

Elongation SSF vs Current Ductile GradesSFF has up to 3 times higher elongation at equal strength levels

22

Tensile tests curves Ferritic, SFF and ferritic/pearlitic grades

From: Björkegren and Hamberg, Ductile iron with better machinability compared to conventional grades

Foudryman, December 1998, page 386-391.

23

330

320 320

310305

300

290

280

270270

260 260

250

240

230230 230 225 230 230

220 Perlitic

210 215 SSF210

200 200 200 200 200 ADI

190 190

180 182

170 170 170

160 160

150

GJS-700 GJS-800 (ADI)

Bri

nel

l Har

dn

ess

GJS-450 GJS-500 GJS-600

Brinell HardnessSFF shows lower average hardness and less variation in hardness,

piece to piece and within a piece

24

Comparison of Impact energy

Source ÖGI Sirion projekt

Charpy V-Impact test specimen

Test temperature [ºC]

25

Fatigue StrengthRotating Bending, R= -1, Machined Surface

Steering knuckles (prGJS-600-10: 83% Nodularity)

250

300

350

400

450

500

550

600

650

700

1,0E+02 1,0E+03 1,0E+04 1,0E+05 1,0E+06 1,0E+07

Number of cycles till failure

Str

es

s a

mp

litu

de

(M

Pa

)

GJS-600-10

GJS-700-2

GJS-800-10

No difference in fatique limit for SSF compared to normal pearlitic cast iron,

ADI has best fatique properties for machined specimens.

26

Influence of Nodularity on ElongationSilicon % has higher influence as nodularity

0

2

4

6

8

10

12

14

16

18

20

60 65 70 75 80 85 90 95 100

Nodularity (= Graphite Form V + Vl) (%)

Elo

ng

ati

on

(%

)

Si = 3,85 - 4,05 %

Si = 4,25 - 4,45 %

Si = 4,68 %

Si = 4,90 %

Si too high

Low nodularity,

elongation stil > 13%

27

Mechanical properties SSF vs EN 10293 Cast Steels

MATERIAL DESIGNATION YIELD STRESS MPA TENSILE STRENGTH ELONGATION HARDNESS IMPACT ENERGY*

Rp0,2 Rm A HBW V-Notched at RT

MPa MPa % J

min. min. min.

GJS 450-18 350 450 18 170 – 200 9

GE240 (+N) 240 450 17 MIN.~ 130 27

GJS 500-14 400 500 14 185 – 215 3

G20MN5 (+N) 300 480 20 MIN.~ 150 27

GJS 600-10 470 600 10 200 – 230 2 – 3

GE300 (+N) 300 600 15 MIN.~ 165 31

G42CRM04 (+QT) 600 800 12 - 31

* V-notched Charpy test samples, at room temperature. Source: EN 1563:2012 & EN 10293

N: Normalized, QT: Quenched & Tempered

28

Average chemical analysis SSF and Ferritic to Pearlitic Ductile Irons

* These chemical analyses are only guidelines. The final analysis is tailored according to customers needs.

MATERIAL DESIGNATION C Si Mn Cu

GJS 450-10 3.5 – 3.7 2.0 – 2.5 < 0.5 0.10 – 0.25

GJS 450-18 3.1 – 3.3 3.2 < 0.5 < 0.1

GJS 500-7 3.5 – 3.7 2.0 – 2.5 < 0.5 0.3 – 0.4

GJS 500-14 3.0 – 3.2 3.8 < 0.5 < 0.1

GJS 600-3 3.5 – 3.7 2.0 – 2.5 < 0.5 0.4 – 0.5

GJS 600-10 2.8 – 3.0 4.3 < 0.5 < 0.1

GJS 700-2 3.5 – 3.7 2.0 – 2.5 < 0.5 0.8 – 1.0

29

Specific density

1,5% weight saving compared to

“normal” ductile iron!

Source ÖGI Sirion projekt

30

22.10.201531

MACHİNABİLİTY

Variation of Hardness in section of Wheel Hubs

From: Björkegren and Hamberg, Ductile iron with better

machinability compared to conventional grades

Foudryman, December 1998, page 386-391.

Reduced variation and lower average

hardness results in 10-20 % lower

machining costs

32

Difference in metal matrix

33

Tool Life

Source IfG Sirion projekt

Tool life till 200 µm flange wear

Cutting speed 240m/min

Cutting speed 2320m/min

Tool lif

e in m

in

34

Surface roughnessInfluence of metalic matrix on surface roughness and shape of chips

Source IfG Sirion projekt

Ro

ug

ne

ss R

z/µ

m

35

22.10.201536

SOMEEXAMPLESSSF DESİGNS

Agriculture: Rear Axle

SSF grade: EN-GJS-600-10

Fabricated part converted into a casting, huge cost saving, increased loads possible

37

Agriculture: Steering knuckle

Redesigned; reduced weight and increased load, replaces steel forging

SSF Grade: EN-GJS-600-10

38

Highway Bus: Air Spring Member

Redesigned; weight saving, 8 mm wallthickness

SSF Grade: EN-GJS-500-14

39

Agriculture: Support for exhaust pipe

Weight saving, combining functions

SSF Grade: EN-GJS-500-14

40

22.10.201541

EXPERIENCES

41

Experiences

42

• “Imperfections”/”Discontinuities” ;

• Ductile Iron slag, porosities, nodularity

• Spectrometer

• Nodularity sample

Porosities in stub

43

Chunky Graphite

44

Deviation in graphite shape in SFFchain of small nodules

45

Chunky GraphiteInfluenced by wall thickness

46

• Chunky graphite, partly due to too high Ce-content in FeSiMg.

• Measures :

• Low Ce-containing FeSiMg

• Addition of antimony

• Reduced Si%

Influence of Inoculation on nodularity

47

Increasing

Silicon

content

Good

inoculation

Poor

inoculation

Chemical

composition

inoculant

Nodula

rity

(S

hape V

+ V

I

Wall thickness

Comparison Spectro with Wet chemical Analysis

48

Yas (wet

chemical)

Si increased by

inoculation

22.10.201549

COST IMPACT AND HOW TO ACT

How to get the most out of SSF

Do not copy current design 100% into the new design

• Except for test purposes to compare the SFF with current grades

Start more or less from scratch

• Use the better mechanical properties like

• higher 0.2% proof strength values

• higher elongation rates

Think “Out of the Box”

Work together with the supplier to optimize the casting design as early as

possible

50

22.10.201551

SUMMARY

Advantages of HiSi / SSF

Higher yield strength – 13 to 27% improvement

Better elongation – up to 3.3 times

Higher yield and better elongation can lead to a reduction of weight of

the components

Uniform metallic matrix (fully ferritic vs ferritic to pearlitic)

More uniform hardness distribution and mechanical properties

Better machinability

Comparable or better fatigue properties

Not so sensitive to low nodularity, because of the solution

strengthening effect

20 % of non-spheroidal graphite is accepted in EN1563

52

Advantages of HiSi / SSF

Less sensitive to carbide formation in thin walled sections

Possibility to design thinner sections

Improved weldability

When converting from steel, a weight saving of at least to 9% due to

density reduction

(from 7.8 kg/dm^3 to 7.05 kg/dm^3)

Resulting in:

Up to 10% - 20% weight saving possible in design

Up to 10% - 25% lower machining costs

53

Downside

• No surface hardening possible

• More sensitive for chunky graphite formation (> 60 mm wall thickness)

• Base chemical composition different from other qualities of cast iron

Ferritic-to-Pearlitic matrices are only justified when hardness (as-cast /

surface hardened) is more important than all other properties: yield strength,

ductility, fatigue strength, machinability, dimensional accuracy, etc.

54

Thank you !